Uncoupling Mat

ABSTRACT

An uncoupling mat includes a flexible plastic layer ( 2 ) made of film-like plastic with structuring that defines indentations ( 6 ) provided with undercuts ( 5 ) on the first side ( 4 ) and cavities ( 8 ) positioned between the indentations ( 6 ) on the opposite second side ( 7 ). A fleece or fabric ( 3 ) is securely connected to the second side ( 7 ) and covers the cavities ( 8 ). A cross-section of the indentations ( 6 ) in at least some corner regions ( 10 ) increases towards the first side ( 4 ).

PRIORITY CLAIM

This application is a continuation of U.S. patent application Ser. No.15/914,223, filed Mar. 7, 2018, and claims priority of and to GermanPatent Application Serial No. 20 2017 101 349.9, filed Mar. 9, 2017,each of which is hereby incorporated herein by reference in its entiretyfor all purposes.

BACKGROUND OF THE INVENTION

Uncoupling mats are used to uncouple a substrate and a slab coveringlaid over the latter in terms of stress such that the transmission ofstresses that develop in particular within the substrate to the slabcovering is prevented. In this manner, the development of cracks in theslab covering or the detachment of individual tiles can be prevented.

BRIEF SUMMARY OF THE TECHNOLOGY

In accordance with one aspect of the invention, an uncoupling mat isprovided that includes a flexible plastic layer (2) made of film-likeplastic with structuring that defines indentations (6) provided withundercuts (5) on the first side (4) and cavities (8) positioned betweenthe indentations (6) on the opposite second side (7). A fleece or fabric(3) can be securely connected to the second side (7) and can cover thecavities (8). A cross-section of the indentations (6) in at least somecorner regions (10) increases towards the first side (4).

In accordance with another aspect of the invention, an uncoupling mat isprovided, including a flexible plastic layer made of a film-like plasticwith structuring that defines indentations provided with undercuts onthe first side and cavities positioned between the indentations on theopposite second side, and a fleece or fabric securely connected to thesecond side and covering the cavities. The mat can be characterised inthat the plastic layer can be provided with a plurality of weakeningzones which extend continuously between opposing side edges of theplastic layer.

In accordance with another aspect of the invention, an uncoupling mat isprovided, including a plastic layer made of film-like plastic withstructuring that defines indentations provided with undercuts on thefirst side and cavities positioned between the indentations on theopposite second side, and a fleece or fabric securely connected to thesecond side and covering the cavities, in particular an uncoupling mataccording to any of the preceding claims, characterised in that thecross-section of the indentations in at least some corner regionsincreases towards the first side, in particular increases constantly,preferably from the bottom of the corresponding indentation.

BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS

Further features and advantages of the present invention become clearfrom the following description of embodiments of uncoupling matsaccording to the invention with reference to the attached drawings.These show as follows:

FIG. 1 a schematic perspective partial view of an uncoupling mataccording to a first embodiment of the present invention;

FIG. 2 an enlarged side view of the portion provided with reference signII in FIG. 1 and which shows a weakening zone;

FIG. 3 a top view of the arrangement shown in FIG. 1;

FIG. 4 a view similar to FIG. 2, which shows an alternative embodimentof a weakening zone;

FIG. 5 a side view of the arrangement shown in FIG. 1 in the correctlylaid state;

FIG. 6 a schematic top view of an uncoupling mat according to a secondembodiment of the present invention;

FIG. 7 a cross-sectional view along line VII-VII in FIG. 6, and

FIG. 8 a cross-sectional view along line VIII-VIII in FIG. 6.

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates generally to an uncoupling mat comprisinga flexible plastic layer made of a film-like plastic with structuringthat defines indentations provided with undercuts on the first side andcavities positioned between the indentations on the opposite secondside, and a fleece or fabric securely connected to the second side andcovering the cavities.

Uncoupling mats of the type specified are used to uncouple a substrateand a slab covering laid over the latter in terms of stress such thatthe transmission of stresses that develop in particular within thesubstrate to the slab covering is prevented. Thus, the development ofcracks in the slab covering or the detachment of individual tiles can beprevented. For this purpose, in a first step uncoupling mats arenormally fastened to the substrate using an adhesive that grips in thefleece or fabric. The adhesive can be, for example, a thin bed mortar, areaction resin mortar or the like, reference only being made to thin bedmortar in the following for the sake of simplicity. In a further stepthe slab covering is then laid over the plastic layer of the uncouplingmat, once again using thin bed mortar, the thin bed mortar anchoring inthe indentations provided with undercuts such as to form thin bed mortarstilts. In this way a secure connection between the substrate and theslab covering is achieved overall. Any stresses that are present withinthe substrate, caused for example by the remaining drying and curingprocess of the substrate, by the so-called settling of a construction,by temperature changes due to different thermal expansion coefficientsof the materials used or the like, are then absorbed in the compositeand compensated for by corresponding deformation of the uncoupling matsso that they can not be transmitted to the slab covering. The freedom ofmovement of the uncoupling mat required for this is provided by thecavities formed on the second side of the plastic layer. Reference ismade in this connection, for example, to the uncoupling mats describedin publications DE 37 01 414 A1 and EP 1 073 813 B2, to the entiredisclosure of which reference is herewith made.

DE 37 01 414 A1 describes an uncoupling mat, the plastic layer of whichhas concertina-like structuring, the indentations defined on the firstside as well as the cavities defined on the second side being in theform of dovetails, and each extending parallel to one another. In thisway, due to the structure, the freedom of movement of the uncoupling matrequired for the uncoupling is provided substantially in a directiontransverse to the direction of the extension of the cavities.

In contrast, on the basis of DE 37 01 414 A1, EP 1 073 813 B2 proposesan uncoupling mat with a plastic layer the structuring of which hascavities that cross in a grid on the second side and indentationsprovided with undercuts and delimited by the cavities on the first side.With this uncoupling mat therefore, use is not made of the uncouplingprinciple brought about by the concertina-like structuring of theplastic layer described in DE 37 01 414 A1. Rather, in the uncouplingmat described in EP 1 071 813, one relies upon the extensibility of thefilm-like plastic to achieve the uncoupling effect which allows movementof the thin bed mortar stilts formed in the indentations in thedirection of the cavities with deformation of the plastic layer.

Fundamentally, it is desirable to further improve the uncouplingcapability of known uncoupling mats.

Furthermore, it is desirable to improve the clamping of the lower sideof known uncoupling mats which is formed by the fleece or the fabricwith a thin bed mortar.

In addition, one disadvantage of known uncoupling mats is that uponfilling the indentations with a thin bed mortar, the air can often notcompletely escape from the indentations, and so air inclusions developwhich form uncontrolled cavities within the mortar, and this is notdesirable.

On the basis of this prior art it is an object of the present inventionto devise an uncoupling mat of the type specified at the start with analternative structure.

In order to achieve this object, the present invention devises anuncoupling mat of the type specified at the start which is characterisedin that the plastic layer is provided with a plurality of weakeningzones which extend continuously between opposing side edges of theplastic layer. In other words, the present invention proposes furtherimproving the uncoupling capability of an uncoupling mat of the typedescribed in EP 1 073 813 B2 by the formation of additional weakeningzones. By means of the weakening zones the plastic layer is givenstructurally an additional possibility for movement substantiallytransversely to the direction of extension, in particular in a straightline, of the weakening zones which is supplemented by the freedom ofmovement provided by the cavities, as a result of which an uncouplingmat with clearly improved uncoupling capability is provided overall.

The weakening zones are preferably provided in the form of grooves, thegrooves possibly having, for example, a semi-circular, semi-ellipticalor a V-shaped or triangular cross-section. In this way the uncouplingmat according to the invention can be produced with a simple structure.

According to one embodiment of the present invention the plastic layerhas a substantially constant thickness, the thickness being smaller inthe region of the weakening zones. In this way, targeted weakening ofthe plastic layer is therefore brought about not only structurally, butalso by a smaller thickness of the plastic layer in the region of theweakening zones.

Preferably, a first group of weakening zones extending parallel to oneanother is provided, which weakening zones extend in particulartransversely to a longitudinal direction of the uncoupling mat, forexample perpendicular to the longitudinal direction. If the uncouplingmat is formed longitudinally, i.e. rectangularly as viewed from above,with a shorter and a longer side edge, the longitudinal directionadvantageously corresponds to the direction of extension of the longerside edge. In this way additional uncoupling is provided whichcompensates for stresses acting in particular substantiallyperpendicularly to the direction of extension of the first group ofweakening zones.

Advantageously, a second group of weakening zones extending parallel toone another is provided which crosses the first group, in particular ata right angle. Accordingly, a further additional uncoupling effect isprovided which in particular compensates for stresses actingsubstantially perpendicular to the direction of the extension of thesecond group of weakening zones. It should be clear that more than twogroups of weakening zones extending parallel to one another, and whichcross one another, may also be provided.

Advantageously, the weakening zones are arranged spaced apart from oneanother equally, the distances preferably being in the range of from 10to 100 mm, in particular in the range of from 10 to 50 mm. It has beenshown that these distances have a good uncoupling effect within theranges specified.

Advantageously, the weakening zones each extend between two rows ofindentations, i.e. not through the indentations themselves. Weakeningzones can be formed here between each row of indentations. Alternativelyhowever, it is also possible to provide weakening zones, for example,only between every second or third row of indentations.

In order to achieve the object specified at the start, the presentinvention furthermore devises an uncoupling mat of the type specified atthe start which is characterised in that the fleece or fabric hasthrough holes with a cross-section in the range of from 0.5 to 1.0 mm²,in particular in the range of from 0.5 of 0.8 mm². Such small throughholes with a cross-section within said range are characterised in thatthey allow the passage of thin bed mortar in the conventionally usedconsistency with the normal manual contact pressure of the uncouplingmats that is involved when they are being laid, whereupon the thin bedmortar can not only grip to the fleece or the fabric, but also behindthe latter, clogging of the cavities that are essential for theuncoupling effect with thin bed mortar being reliably avoided however.

Furthermore, the present invention devises an uncoupling mat of the typespecified at the start which is characterised in that the indentationshave corner regions, the cross-section of the indentations in at leastsome corner regions increasing towards the first side, in particularconstantly increasing, preferably from the bottom of the correspondingindentation. Corner regions configured in this way lead to air beingable to escape well while thin bed mortar is being applied to the firstside of the plastic layer of the uncoupling mat with an appropriatetrowel, as a result of which air inclusions and the formation ofuncontrolled cavities associated with the latter are able to beprevented, and good and consistent filling of the indentations with thinbed mortar are guaranteed.

According to a first version of the uncoupling mat according to theinvention the cavities cross one another and define a grid- or net-likearrangement. In this way almost consistent and good uncoupling isguaranteed in all directions.

Advantageously, the uncoupling mat in this version has 100 to 3000indentations per square metre, as a result of which the uncouplingfunction is also optimised.

According to a second version of the uncoupling mat according to theinvention the indentations cross one another and define a grid- ornet-like arrangement.

In this second version the uncoupling mat preferably has 100 to 3000cavities per square metre, as a result of which the uncoupling functionis optimised.

In the second version the cavities can at least partially have anannular cross-section. This means that additional recesses are formed onthe opposite side, as a result of which the bearing capacity of anarrangement produced with the uncoupling mat is improved.

According to one embodiment of the present invention the indentationshave a minimum width in the range of from 3 to 20 mm and a maximumheight in the range of from 2 to 20 mm.

Turning now the figures, FIGS. 1 to 5 show an uncoupling mat 1 accordingto an embodiment of the present invention which has, as main components,a plastic layer 2 and a fleece or fabric 3, and which can be provided ina sheet or a roll.

The plastic layer 2 is produced from film-like plastic and has asubstantially consistent thickness d which is normally in the rangebetween 0.4 and 1.0 mm. Accordingly, the plastic layer 2 is extensible,i.e. it can be deformed manually. The plastic layer 2 is provided withstructuring which on a first side 4, which in the correctly laid stateof the uncoupling mat 1 forms the upper side, defines indentations 6provided with undercuts 5, and on the opposite second side 7 definescavities 8 arranged between the indentations 6, which cavities in thepresent case cross one another and form a grid-like arrangement. Theindentations 6 provided in a regular arrangement preferably have aminimum width B_(min) in the range of from 3 to 20 mm and a maximumheight H_(max) in the range of from 2 to 8 mm, their number being inparticular 500 to 3000 per square metre. In this case the indentations 6are substantially cuboid in form, the undercuts 5 each being formed by aprojection 9 which projects into the indentation 6. However, it shouldbe clear that the indentations 6 may also differ from the cuboid form,for example, as seen from above, they may also be hexagonal oroctagonal, cross-shaped or circular in form. Likewise, the shape andnumber of the projections 9, and accordingly also of the undercuts 5formed by the latter, may vary. Thus, the side walls which delimit theindentations 6 laterally may also simply have a corresponding incline tothe vertical V (direction perpendicular to the bottom 11) in order toform the undercuts 5. The cross-section of the indentations 6 increasesconstantly in the corner regions 10 from the bottom 11 towards the firstside 4. In the present case this is achieved by the inner edges definingthe corner regions 10 being inclined accordingly with respect to thevertical V. A plurality of weakening zones 12 extend between theindentations 6, which weakening zones extend continuously and preferablyin a straight line between opposing side edges of the plastic layer 2,in the present case perpendicular to the latter and parallel to oneanother. The weakening zones 12 are provided as grooves with asubstantially semi-circular cross-section. Basically, however, thegrooves may also have a cross-sectional form that differs from this,such as for example the form of a semi-ellipse, a triangle or the like.In the embodiment of the weakening zones 12 shown in FIG. 2, thethickness d is constant in relation to the thickness d of the otherplastic layer 2. However, it may also be smaller, as shown by way ofexample in FIG. 4, as a result of which an additional weakening effectis achieved. The weakening zones 12 are spaced apart equally from oneanother, the distances preferably being in the range of from 10 to 100mm, in particular in the range of from 10 to 50 mm. The weakening zones12 may be formed here between each row of indentations 6. Alternativelyhowever, they may also be provided only between every second or thirdrow of indentations 6, to give just one example. The distances betweenthe parallel weakening zones 12 in the longitudinal direction L and thetransverse direction Q of the uncoupling mat 1 may also be different.Moreover, weakening zones 12 may also be formed only transversely to thelongitudinal direction L or only transversely to the transversedirection Q.

The fleece or fabric 3 is connected securely to the second side 7 of theplastic layer 2 and accordingly covers the cavities 8 thereof. Thus, thefleece or fabric 3 may be laminated onto the second side 7 of theplastic layer 2, for example, or be adhered to the latter. The fleece orfabric 3 comprises regularly arranged through holes 13 with across-section in the range of from 0.5 to 1.0 mm², in particular in therange of from 0.5 to 0.8 mm².

The uncoupling mat 1 serves to uncouple a substrate 14 and a slabcovering 15 laid over the latter in terms of stress. In a first step, asshown in FIG. 5, it is fastened to the substrate 14 using a thin bedmortar 16. The thin bed mortar 16 is mostly applied to the substrate 14here using a trowel and/or a toothed trowel, whereupon the uncouplingmat 1 is positioned and pressed onto the substrate. At this juncture thethin bed mortar grips in the fleece or fabric 3, as a result of which afirst fixing is brought about. A fleece is advantageous in that itconsists of a plurality of small individual threads which also projectoutwards, as a result of which a profound connection to the thin bedmortar 16 is achieved. In the case of a fabric, this should also haveprojecting individual threads in the manner of a fleece so as to alsobring about the appropriate effect. By virtue of the chosencross-section of the through holes 13, the latter are sufficiently largefor the thin bed mortar 16 to penetrate the fleece or fabric 3 slightly,as a result of which further fixing is achieved by the anchoring of thethin bed mortar 16 behind the fleece or fabric 3, but they are alsosufficiently small, and this reliably prevents the cavities 8 of theuncoupling mat 1 from completely clogging with thin bed mortar 16.

In a second step the slab covering 15, for example in the form of tiles,is then laid over the plastic layer 2 of the uncoupling mat 1, onceagain using thin bed mortar 16, the thin bed mortar 16 anchoring in theindentations 6 provided with undercuts 5. When distributing the thin bedmortar 16 over the plastic layer 2 with a trowel and/or a toothedtrowel, it is ensured by virtue of the design of the corner regions 10of the indentations 6 that any air that is present in the indentations 6can escape without any problem, as a result of which the formation ofcavities between the uncoupling mat 1 and the slab covering 15 issuppressed, and complete filling of the indentations 6 with thin bedmortar 16 is also guaranteed.

If stresses now occur in the substrate 14, caused for example by theremaining drying and curing process of the substrate 14, by theso-called settling of a construction, by temperature changes due todifferent thermal expansion coefficients of the materials used or thelike, these stresses are thus absorbed and compensated for bycorresponding deformation of the uncoupling mat 1 so that they can notbe transmitted to the slab covering 15. The freedom of movement of theuncoupling mat 1 required for this is on the one hand provided by thecavities 8 formed on the second side 7 of the plastic layer 2, whichcavities allow movement of the thin bed mortar stilts formed in theindentations 6 in the direction of the cavities 8. On the other hand,the weakening zones 12 enable expansion and/or compression of theplastic layer, in each case respectively perpendicular to the directionof extension of the weakening zones 12, as a result of which additionaluncoupling is provided.

FIGS. 6 to 8 show an uncoupling mat 1 according to a second embodimentof the present invention which also has, as main components, a plasticlayer 2 and a fleece or fabric 3. The uncoupling mat 1 according to thesecond embodiment only differs from the previously described embodimentwith regard to the structuring of the plastic layer 2. In the presentcase the structuring defines on the first side 4, which in the correctlylaid state of the uncoupling mat 1 forms the upper side, indentations 6provided with undercuts 5, which indentations are made in the form ofchannels and form a grid-like arrangement. On the opposite second side 7the structuring defines cavities 8 arranged between the indentations 6,which cavities in this case are in an octagonal annular form so that arecess 17 develops in the middle of an annular cavity 8 on the firstside 4. The indentations 6 have a cross-section which is adapted to thediameter of a cable 18, in particular a heating cable, such that thecable 18 can be held, clamped in the indentations 6, as shown by way ofexample in FIGS. 6 and 7. The weakening zones 12 extend in the middle ofthe indentations 6 in the longitudinal and transverse direction of theuncoupling mat 1, which weakening zones in the present case are formedsimilarly to the weakening zone 12 shown in FIG. 2, only that they arecurved upwards and not downwards. It should be pointed out that the formof the indentations 6 and cavities 8 may vary. Thus, the cavities mayalso have a form that differs from an octagonal annular form, to givejust one example.

It should be clear that the embodiments described above only serve asexamples, and they are in no way to be understood to be restrictive. Infact, changes and/or modifications are possible, without straying fromthe scope of protection of the present application which is defined bythe attached claims. In particular, individual features of theembodiments that are described may be substituted.

LIST OF REFERENCE SIGNS

-   1 uncoupling mat-   2 plastic layer-   3 fleece/fabric-   4 first side-   5 undercut-   6 indentation-   7 second side-   8 cavity-   9 projection-   10 corner region-   11 bottom-   12 weakening zone-   13 through hole-   14 substrate-   15 slab covering-   16 thin bed mortar-   17 recess-   18 cable-   B_(min) minimum width-   H_(max) maximum height-   d thickness-   V vertical-   L longitudinal direction-   Q transverse direction

I claim:
 1. An uncoupling mat (1) comprising: a flexible plastic layer(2) made of film-like plastic with structuring that defines indentations(6) provided with undercuts (5) on the first side (4) and cavities (8)positioned between the indentations (6) on the opposite second side (7),and a fleece or fabric (3) securely connected to the second side (7) andcovering the cavities (8), wherein a cross-section of the indentations(6) in at least some corner regions (10) increases towards the firstside (4).
 2. The uncoupling mat (1) according to claim 1, wherein thecross-section of the indentations (6) in at least some corner regions(10) increases constantly towards the first side (4).
 3. The uncouplingmat (1) according to claim 1, wherein the cross-section of theindentations (6) in at least some corner regions (10) increasesconstantly towards the first side (4) from the bottom (11) of thecorresponding indentation (6).
 4. The uncoupling mat (1) according toclaim 1, wherein the plastic layer (2) is provided with a plurality ofweakening zones (12) which extend continuously between opposing sideedges of the plastic layer (2).
 5. The uncoupling mat (1) according toclaim 4, wherein in the weakening zones (12) comprise grooves.
 6. Theuncoupling mat (1) according to claim 4, wherein the plastic layer (2)has a substantially constant thickness (d), the thickness (d) beingsmaller in the region of the weakening zones (12).
 7. The uncoupling mat(1) according to claim 4, wherein at least some of a first group ofweakening zones (12) extend parallel to one another, said parallelweakening zones extending transversely to a longitudinal direction ofthe uncoupling mat (1).
 8. The uncoupling mat (1) according to claim 7,wherein at least some of a second group of weakening zones (12) extendparallel to one another, the second group of parallel weakening zonescrossing the first group of parallel weakening zones at right angles. 9.The uncoupling mat (1) according to claim 4, wherein the weakening zones(12) are arranged spaced apart from one another equally at distancesbeing in the range of from 10 to 100 mm.
 10. The uncoupling mat (1)according to claim 9, wherein the weakening zones (12) are spaced atdistances being in the range of from 10 to 50 mm.
 11. The uncoupling mat(1) according to claim 4, wherein the weakening zones (12) each extendbetween two rows of indentations (6).
 12. The uncoupling mat (1)according to claim 1, wherein the fleece of fabric (3) has through holes(13) with a cross-section in the range of from 0.5 to 1.0 mm².
 13. Theuncoupling mat (1) according to claim 12, wherein the through holes (13)include a cross-section in the range of from 0.5 to 0.8 mm².
 14. Theuncoupling mat (1) according to claim 1, wherein the cavities (8) crossone another and define a grid- or net-like arrangement.
 15. Theuncoupling mat (1) according to claim 14, wherein the mat includes 100to 3000 indentations (6) per square metre.
 16. The uncoupling mat (1)according to claim 1, wherein the indentations (6) cross one another anddefine a grid- or net-like arrangement.
 17. The uncoupling mat (1)according to claim 16, wherein the mat includes 100 to 3000 cavities (8)per square metre.
 18. The uncoupling mat (1) according to claim 17,wherein the cavities (8) at least partially have an annularcross-section.
 19. The uncoupling mat (1) according to claim 18, whereinthe indentations (6) have a minimum width (B_(min)) in the range of from3 to 20 mm.
 20. The uncoupling mat (1) according to claim 1, wherein theindentations (6) have a minimum width (B_(min)) in the range of from 3to 20 mm and a maximum height (H_(max)) in the range of from 2 to 20 mm.